BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a system for calculating the remaining capacity
of an energy storage device such as a secondary battery or an electrochemical capacitor.
2. Description of the Related Art
[0002] The miniaturization of energy storage devices such as secondary batteries including
nickel metal hydride batteries and lithium-ion batteries, and electrochemical capacitors
including electric double layer capacitors is advancing, and the increase of the energy
densities thereof is also encouraged. Those energy storage devices are actively used
as power sources for portable information communication devices, electric vehicles,
and hybrid electric vehicles.
[0003] To effectively utilize the energy storage device, grasping the accurate residual
or remaining capacity (hereinafter referred to as remaining capacity) thereof is of
importance. A first approach of integrating the charge and discharge current of an
energy storage device to calculate the remaining capacity thereof and a second approach
of obtaining the remaining capacity of the energy storage device based on its open
circuit voltage are known. The first approach has an advantage in that the obtained
remaining capacity is not influenced by the load fluctuation in the energy storage
device caused by rush current, but has a disadvantage in that a cumulative error often
occurs (particularly, the error may increase during high-load conditions). The second
approach has an advantage in that the efficiency is high so long as the open circuit
voltage is estimated with accuracy but has a disadvantage in that even when load significantly
changes for a short time, the calculated remaining capacity easily varies. Accordingly,
various techniques of calculating the remaining capacity utilizing the above two approaches
are provided.
[0004] For example, Japanese Unexamined Patent Application Publication No. 6-242193 (Patent
Document 1) discloses a technique of obtaining the remaining capacity of a battery
on the basis of its open circuit voltage obtained from the battery voltage measured
when an electric vehicle stops, detecting the discharged capacity based on the integrated
value of the discharge current of the battery, and calculating the fully-charged capacity
on the basis of the discharged capacity and the remaining capacity during the stop,
thus obtaining the remaining capacity from the fully-charged capacity and the discharged
capacity.
[0005] Japanese Unexamined Patent Application Publication No. 8-179018 (Patent Document
2) discloses a technique of calculating the remaining capacity of a battery such as
a lithium-ion battery, in which the battery capacity and the battery voltage have
linear proportional relationship, on the basis of current integration obtained after
discharging or charging the battery for an arbitrary period, the voltage before discharging
or charging, and the voltage after discharging or charging.
[0006] In addition, Japanese Unexamined Patent Application Publication No. 11-223665 (Patent
Document 3) discloses a technique of compensating the calculation of the remaining
capacity of a battery on the basis of the rate of change in difference between the
remaining capacity obtained by integrating the charge and discharge current of the
battery and the remaining capacity estimated based on the open circuit voltage thereof.
[0007] According to the technique disclosed in Patent Document 1, however, the accuracy
with which the remaining capacity of the battery is calculated while the electric
vehicle is running is not ensured. The open circuit voltage is obtained based on the
battery voltage measured when the vehicle stops. In electric vehicles, however, even
when its motor stops, current flows in a load, e.g., an inverter. Accordingly, the
accurate open circuit voltage is not always detected. Therefore, the technique of
Patent Document 1 is of limited application. It is difficult to apply this technique
to hybrid electric vehicles in which charging and discharging are repeated.
[0008] Similarly, according to the technique disclosed in Patent Document 2, the battery
voltage before or after charging and discharging is regarded as the open circuit voltage.
For the above-mentioned reason, the open circuit voltage is not always detected with
accuracy. In addition, this technique intends to improve the accuracy upon discharging.
Consideration is not given to the accuracy upon charging. It is difficult to apply
this technique to hybrid electric vehicles in which charging and discharging are repeated.
[0009] Further, according to the technique disclosed in Patent Document 3, only when the
difference between the remaining capacity based on current integration and the estimated
remaining capacity based on the open circuit voltage is greater than a predetermined
value, the calculated remaining capacity is updated. Accordingly, there is a high
probability that the calculated remaining capacity sharply increases upon update.
Therefore, when this technique is applied to a hybrid electric vehicle, an abrupt
change in calculated remaining capacity may adversely affect vehicle control.
SUMMARY OF THE INVENTION
[0010] Accordingly, it is an object of the present invention to provide a system for calculating
the remaining capacity of an energy storage device, the system capable of making full
use of the advantages of the remaining capacity of the energy storage device obtained
based on current integration and those of the remaining capacity thereof obtained
based on its open circuit voltage and also capable of always obtaining the final remaining
capacity with uniform accuracy.
[0011] In brief, according to the present invention, the system includes: voltage detection
means for detecting the terminal voltage of an energy storage device; current detection
means for detecting the charge and discharge current of the energy storage device;
first calculation means for integrating the charge and discharge current detected
by the current detection means to calculate a first remaining capacity; second calculation
means for estimating the open circuit voltage of the energy storage device on the
basis of the terminal voltage detected by the voltage detection means, the charge
and discharge current detected by the current detection means, and the impedance of
the equivalent circuit of the energy storage device to calculate a second remaining
capacity based on the estimated open circuit voltage; and third calculation means
for weighting the first and second remaining capacities with a weight determined depending
on the operating conditions of the energy storage device and combining the weighted
remaining capacities into the remaining capacity of the energy storage device.
[0012] Other features and advantages of the present invention will become more apparent
from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013]
Fig. 1 is a block diagram showing the structure of a system according to an embodiment
of the present invention, the system being applied to a hybrid electric vehicle;
Fig. 2 is a block diagram of an algorithm for estimating the remaining capacity of
a battery;
Fig. 3 is a circuit diagram showing an equivalent circuit model;
Fig. 4 is a flowchart of a process of estimating the battery remaining capacity;
Fig. 5 is an explanatory diagram showing a table of the current capacity;
Fig. 6 is a table explaining the impedance;
Fig. 7 is a table explaining the remaining capacity;
Fig. 8 is a table explaining weight;
Fig. 9 is a diagram explaining the remaining capacity when the moving average of current
is not obtained;
Fig. 10 is a diagram explaining the remaining capacity when the moving average of
current is obtained; and
Fig. 11 is a diagram explaining a result of calculation of the remaining capacity
during actual driving.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Fig. 1 shows an embodiment of the present invention. According to the present embodiment,
a system for calculating the remaining capacity of en energy storage device is applied
to a hybrid electric vehicle (HEV) with the combination of an engine and a motor.
Referring to Fig. 1, an HEV power supply unit 1 includes; a battery 2 which serves
as an energy storage device and is composed of, for example, a plurality of multi-cell
battery packs connected in series; and a calculation unit (electronic control unit
(ECU) for calculation; calculation ECU) 3 for performing energy management, i.e.,
calculating the remaining capacity of the battery 2, controlling cooling or charging
the battery 2, detecting malfunction, and performing the protecting operation upon
detecting malfunction. The battery 2 and the calculation unit 3 are packaged in one
casing.
[0015] In the present embodiment, description will be made on the assumption that a lithium-ion
secondary battery is used as an energy storage device. The remaining capacity calculating
method according to the present invention can also be applied to electrochemical capacitors
and other secondary batteries.
[0016] The calculation unit 3 includes a microcomputer and calculates the state of charge
(SOC), i.e., the remaining capacity SOC(t) of the battery 2 every predetermined time
t on the basis of the terminal voltage V of the battery 2 measured by a voltage sensor
4, the charge and discharge current I of the battery 2 measured by a current sensor
5, and temperature (cell temperature) T of the battery 2 measured by a temperature
sensor 6.
[0017] The remaining capacity SOC(t) is output from the calculation unit 3 of the power
supply unit 1 to an electronic control unit (HEV ECU) 10 for HEV control through,
for example, a controller area network (CAN) communication line. The remaining capacity
SOC(t) is used as basic data for vehicle control, i.e., data to display the battery
remaining capacity or warning. In addition, the remaining capacity SOC(t) is also
used as data (a base value in calculating the remaining capacity based on current
integration which will be described below) SOC(t-1) in the preceding operation period.
[0018] The HEV ECU 10 includes a microcomputer similar to the calculation unit 3 and performs
control for the operation of the HEV and other necessary controls based on instructions
of a driver. Specifically, the HEV ECU 10 detects the state of the vehicle on the
basis of a signal from the power supply unit 1 and signals from sensors and switches
(not shown) and controls components, e.g., an inverter 20, an engine (not shown),
and an automatic transmission (not shown) through dedicated control units (not shown).
Alternatively, the HEV ECU 10 directly controls the above components. The inverter
20 converts DC power supplied from the battery 2 into AC power to drive a motor 15.
[0019] The calculation of the remaining capacity SOC by the calculation unit 3 is executed
according to an estimation algorithm shown in Fig. 2. The SOC estimation algorithm
uses measurable parameters in the battery 2, i.e., the terminal voltage V, the current
I, and the temperature T. According to this algorithm, by functions serving as first
to third calculation means, a remaining capacity SOCc as a first remaining capacity
based on current integration and a remaining capacity SOCv as a second remaining capacity
based on the estimated battery open circuit voltage Vo are simultaneously calculated,
the calculated remaining capacities SOCc and SOCv are respectively weighted, and the
weighted remaining capacities SOCc and SOCv are then combined into the remaining capacity
SOC. The obtained remaining capacity SOC is generated as the remaining capacity of
the battery 2.
[0020] The remaining capacity SOCc based on the integration of the current I and the remaining
capacity SOCv based on the estimated open circuit voltage Vo have advantages and disadvantages,
respectively. The remaining capacity SOCc based on the current integration is not
influenced by the load fluctuation in the battery caused by rush current but a cumulative
error often occurs. Particularly, the error may increase during high-load conditions.
For the remaining capacity SOCv based on the estimated open circuit voltage Vo, the
accurate value can be substantially obtained under normal conditions. When load significantly
changes for a short time, however, the value may fluctuate.
[0021] According to the present SOC estimation algorithm, therefore, a remaining capacity
SOCc(t) based on the integration of the current I and a remaining capacity SOCv(t)
obtained from the estimated battery open circuit voltage Vo are weighted with a weight
(weighting factor) w, which varies depending on the operating conditions of the battery
2 as needed, and the weighted remaining capacities are then combined into the remaining
capacity SOC(t). Thus, the disadvantages of the remaining capacities SOCc and SOCv
cancel each other out and the advantages thereof can be fully utilized. The weight
w varies within the range from 0 to 1. The combined remaining capacity SOC(t) is expressed
by the following Expression (1).

[0022] It is necessary to determine the weight w using parameters capable of accurately
representing the present operating conditions of the battery. For the parameters,
the rate of change in current per unit time and the difference between the remaining
capacities SOCc and SOCv can be used. The rate of change in current per unit time
directly reflects the load fluctuation of the battery. However, the simple rate of
change in current is influenced by a rapid change in current, i.e., a current spike.
[0023] According to the present embodiment, therefore, to prevent the influence by an instantaneous
change in current, the rate of change in current subjected to processing related to
the simple average, moving average, or weighted average of predetermined number of
sample data is used. Particularly, in consideration of current delay, the weight w
is determined using the moving average which can properly reflect hysteresis on a
change in the state of charge or discharge of the battery.
[0024] The weight w is determined based on the moving average of the current I. When the
moving average of the current I is large, the weight for the remaining capacity based
on the current integration is increased and that for the remaining capacity based
on the estimated open circuit voltage is reduced. Thus, the influence by the load
fluctuation can be accurately reflected by the remaining capacity based on the current
integration and the fluctuation of the remaining capacity based on the estimated open
circuit voltage can be prevented. On the contrary, when the moving average of the
current I is small, the weight for the remaining capacity based on the current integration
is reduced and that for the remaining capacity based on the estimated open circuit
voltage is increased. Consequently, the influence of the cumulative error caused by
current integration can be avoided. The accurate remaining capacity can be calculated
by estimating the open circuit voltage.
[0025] In other words, the moving average of the current I functions as a low-pass filter
for a high frequency component in current. Due to filtering using the moving average,
a current spike caused by load fluctuation during driving can be eliminated without
increasing delay. Thus, the state of the battery can be grasped with accuracy, the
disadvantages of the remaining capacities SOCc and SOCv can cancel each other out,
and the advantages thereof can be fully utilized. The accuracy of estimating the remaining
capacity can be remarkably increased.
[0026] Further, as the features of the present SOC estimation algorithm, the internal conditions
of the battery are electrochemically grasped based on a theory of battery, thus improving
the accuracy of calculating the remaining capacity SOCv based on the open circuit
voltage Vo of the battery. The calculation of the remaining capacities SOCc and SOCv
according to the present estimation algorithm will now be described in detail.
[0027] First, the remaining capacity SOCc based on the current integration is obtained using
the remaining capacity SOC, combined according to the weight w, as a base value by
integrating the current I every predetermined time as shown in the following Expression
(2):

where,
η: current efficiency,
Ah: current capacity (variable depending on temperature), and
SD: self-discharge rate.
[0028] In Expression (2), the current efficiency η and the self-discharge rate SD can be
regarded as constants (for example, η=1, SD=0). The current capacity Ah varies depending
on temperature. Therefore, in calculating the remaining capacity SOCc based on the
current integration, the current capacity Ah is calculated by measuring a variation
in cell capacity depending on temperature as a function.
[0029] Specifically, the calculation of the remaining capacity SOCc(t) using Expression
(2) is performed by discrete time processing through the calculation ECU 3. The remaining
capacity SOCc(t-1) combined in the preceding operation period is input as a base value
(delay operator Z
-1 in Fig. 2) for current integration. Therefore, error is not accumulated or diverged.
Even when an initial value is remarkably different from a true value, the value converges
on the true value after a predetermined lapse of time (e.g., several minutes).
[0030] On the other hand, to calculate the remaining capacity SOCv based on the estimated
open circuit voltage Vo, the internal impedance Z of the battery is first obtained
using an equivalent circuit model shown in Fig. 3. Parameters, i.e., resistances R1
to R3 and capacitances C1, CPE1, and CPE2 (CPE1 and CPE2 represent double layer capacitances)
are connected in series and parallel in the equivalent circuit model. The parameters
are determined by curve fitting using the well-known Cole-Cole plot according to the
alternating current impedance method.
[0031] The internal impedance Z obtained from those parameters greatly varies depending
on the temperature, the electrochemical reaction rate, the frequency component of
charge and discharge current of the battery. Therefore, instead of the frequency component,
the above-mentioned moving average of the current I per unit time is used as a parameter
to determine the internal impedance Z. The impedance is measured based on the moving
average of the current I and the temperature T to store data. After that, a table
regarding the impedance Z (impedance table in Fig. 6 which will be described below)
is constructed on the basis of the moving average of the current I per unit time and
the temperature T. The impedance Z is obtained using the table. An estimation value
of the open circuit voltage Vo is obtained using the following Expression (3) on the
basis of the impedance Z and the measured terminal voltage V and current I.

[0032] As mentioned above, the moving average of the current I is also used as the parameter
to determine the weight w. The weight w and the impedance Z can be easily calculated
using the moving average. Specifically, as temperature becomes lower, the internal
impedance of the battery becomes higher, resulting in a decrease in the rate of change
in current. As will be described below, the weight w and the impedance Z are determined
using the compensated rate of change in current KΔI/Δt, obtained by temperature-compensating
the moving average of the current I.
[0033] After the open circuit voltage Vo is estimated, the remaining capacity SOCv is calculated
based on the electrochemical relationship in the battery. Specifically, the relationship
between the open circuit voltage Vo and the remaining capacity SOCv is expressed using
the well-known Nernst's equation describing the relationship between the electrode
potential and the activity of ion in equilibrium. Thus, the following Expression (4)
is obtained:

where,
E: normal electrode potential (E=3.745 in the lithium-ion battery according to the
present embodiment),
Rg: gas constant (8.314J/mol-K),
T: temperature (absolute temperature K),
Ne: ionic valence (Ne=1 in the lithium-ion battery according to the present embodiment),
and
F: Faraday constant (96485C/mol).
[0034] In Expression (4), Y denotes a correction term and expresses the voltage-SOC characteristic
at normal temperature as a function of SOC. When SOCv=X, Y can be expressed as a three-dimensional
function of SOC as shown in the following Expression (5).

[0035] The strong correlation among the remaining capacity SOCv, the open circuit voltage
Vo, and the temperature T is found from Expression (4). In this instance, the remaining
capacity SOCv can be calculated using the open circuit voltage Vo and the temperature
T as parameters and Expression (4). Actually, it is necessary to consider the charge
and discharge characteristics of a battery to be used and the operating conditions
thereof.
[0036] To grasp the actual state of the battery from the relationship represented by Expression
(4), therefore, the SOC-Vo characteristic at normal temperature is used as reference
and a charging and discharging test or a simulation is performed in various temperature
ranges, thus storing actual measurement data. A table (remaining capacity table in
Fig. 7 which will be described below) regarding the remaining capacity SOCv obtained
using the open circuit voltage Vo and the temperature T as parameters is constructed
based on the stored actual measurement data. The remaining capacity SOCv is obtained
from this table.
[0037] The calculation of the remaining capacities SOCc and SOCv according to the above-mentioned
SOC estimation algorithm and the combination thereof will now be described with reference
to Fig. 4.
[0038] Fig. 4 shows a flowchart of a fundamental process of estimating the remaining capacity
of the battery. This process is executed by the calculation ECU 3 of the power supply
unit 1. In Fig. 4, for convenience of explanation, the remaining capacity SOCc based
on the current integration is calculated and, after that, the remaining capacity SOCv
based on the estimated open circuit voltage Vo is calculated. Actually, the remaining
capacities SOCc and SOCv are simultaneously calculated.
[0039] The battery remaining capacity estimation process of Fig. 4 is executed every predetermined
time (e.g., every 0.1 seconds). In step S1, whether respective data regarding the
terminal voltage V, the current I, the temperature T, and the remaining capacity SOC(t-1),
combined in the preceding operation period, of the battery 2 are input is determined.
It is assumed that the terminal voltage V is the average of voltages of the battery
packs, the current I is the sum of currents of the battery packs, and the data regarding
the terminal voltage V and the current I are obtained every, for example, 0.1 seconds.
In addition, it is assumed that the temperature T is measured every 10 seconds.
[0040] If no data is newly input in step S1, the process is exited. If new data is input
in step S1, the process proceeds to step S2. In step S2, the current capacity of the
battery is calculated with reference to Fig. 5 which shows a table of the current
capacity. Fig. 5 uses the temperature T as a parameter and shows the ratio Ah' of
the current capacity to the rated capacity (e.g., rated current capacity on condition
that the predetermined number of cells in one battery pack is set to a reference unit)
as a predetermined reference. For the capacity ratio Ah' (=1.00) at a normal temperature
(25°C), as temperature becomes lower, the current capacity also becomes lower, so
that the capacity ratio Ah' becomes larger. The current capacity Ah at every temperature
T to be measured is calculated using the capacity ratio Ah' obtained by reference
to Fig. 5.
[0041] Subsequently, the process proceeds to step S3. The remaining capacity SOCc(t) based
on the current integration is calculated using the current capacity Ah obtained from
Fig. 5, an input value of the current I, the remaining capacity SOC(t-1) combined
in the preceding operation period, and Expression (2). Further, in step S4, the moving
average of the current I is calculated to obtain the rate of change in current per
unit time ΔI/Δt. For example, when the current I is sampled every 0.1 seconds and
the operation period of current integration is 0.5 seconds, the moving average of
five data is obtained.
[0042] In step S5, the impedance Z of the battery equivalent circuit is calculated with
reference to the impedance table of Fig. 6. The open circuit voltage Vo of the battery
2 is estimated based on the obtained impedance Z. The impedance table uses the compensated
rate of change in current KΔI/Δt, obtained by temperature-compensating the rate of
change in current ΔI/Δt (moving average of the current I per unit time), and the temperature
T as parameters and represents the impedance Z of the equivalent circuit. Specifically,
at the same compensated rate of change in current KΔI/Δt, as the temperature T becomes
lower, the impedance Z becomes higher. At the same temperature, as the compensated
rate of change in current KΔI/Δt becomes smaller, the impedance Z becomes higher.
[0043] Subsequently, the process proceeds to step S6. The voltage-SOC characteristic is
calculated to obtain the remaining capacity SOCv. In other words, the remaining capacity
SOCv is calculated using the temperature T and the estimated open circuit voltage
Vo as parameters by reference to the remaining capacity table of Fig. 7. The remaining
capacity table is constructed by grasping the electrochemical state of the battery
according to Nernst's equation. In brief, as the temperature T and the open circuit
voltage Vo become lower, the remaining capacity SOCv becomes smaller. As the temperature
T and the open circuit voltage Vo become higher, the remaining capacity SCOv becomes
larger.
[0044] Figs. 6 and 7 each represent a set of data obtained in normal conditions. Data obtained
in other conditions is not shown.
[0045] Subsequently, the process proceeds to step S7. The weight w is calculated by reference
to a weight table of Fig. 8. The weight table is a one-dimensional table using the
compensated rate of change in current KΔI/Δt as a parameter. Specifically, as the
compensated rate of change in current KΔI/Δt becomes smaller, i.e., as the battery
load fluctuation is smaller, the weight w is set lower, thus reducing the weight for
the remaining capacity SOCc based on the current integration. In step S8, according
to the foregoing Expression (1), the remaining capacity SOCc based on the current
integration and the remaining capacity SOCv based on the estimated open circuit voltage
Vo are weighted with the weight w and are then combined into the final remaining capacity
SOC(t). The present calculation process of one cycle terminates.
[0046] In this instance, the remaining capacity calculation in the case where the moving
average process is performed is compared to that in the case where the moving average
process is not performed. When the moving average of current is not obtained and the
remaining capacity SOCv is calculated, as shown in Fig. 9, abrupt variations in the
remaining capacity SOCv are locally caused by current spikes. Disadvantageously, the
accuracy of the combined remaining capacity SOC is decreased. On the contrary, when
the moving average of current is obtained and the remaining capacity SOCv is calculated,
as shown in Fig. 10, the influence of the current spikes is eliminated from the remaining
capacity SOCv, so that the remaining capacity can be grasped with accuracy on condition
that the load fluctuation is relatively small.
[0047] Fig. 11 shows the calculated remaining capacity during actual driving, i.e., a change
in the remaining capacity SOCc based on the current integration and a change in the
combined remaining capacity SOC on condition that a driving course is relatively full
of ups and downs and cell temperature is substantially 45°C. Referring to Fig. 11,
before an elapsed time of 1500 seconds during which charging and discharging the battery
is repeated, the calculated remaining capacity SOCc based on the current integration
is favorably reflected in the combined remaining capacity SOC. After the elapsed time
of 1500 seconds during which the rate of charging the battery tends to increase, an
increase in the remaining capacity SOCc based on the current integration slows down
and error tends to become larger. The weight for the remaining capacity SOCv (not
shown) based on the estimated open circuit voltage is increased and, therefore, the
weighted remaining capacity SOCv is reflected in the combined remaining capacity SOC.
Consequently, the combined remaining capacity SOC increases with the increased charging
rate. A change in remaining capacity can be grasped with accuracy.
[0048] As mentioned above, when the final remaining capacity is calculated using the remaining
capacity SOCc based on the current integration and the remaining capacity SOCv based
on the estimated open circuit voltage, the respective remaining capacities are optimally
weighted using the weight w set depending on the operating conditions of the battery.
Advantageously, there is no sharp change in the calculated remaining capacity by compensation
at a certain time. A uniform calculation accuracy can be ensured and the remaining
capacity of a battery (energy storage device) can always be obtained.
[0049] In the present invention, it will be apparent that a wide range of different embodiments
can be formed based on this invention without departing from the spirit and scope
of the invention.